Packaging machine with a combined shaping and sealing tool

ABSTRACT

The invention relates to a packaging machine ( 1 ) with a sealing station ( 4 ) which has an upper tool ( 8 ) and a lower tool ( 28 ) and which seals a film web ( 17 ) onto a lower film web ( 20 ). The upper and/or lower tool has means (for example  10 ) for shaping the film web. The invention further relates to a method for sealing a central film onto a lower film web.

The present invention relates to a packaging machine with a combined shaping and sealing station which has an upper tool and a lower tool and which shapes a center film web and seals the latter to a lower film web. The present invention furthermore relates to a method for shaping and sealing a center film web to a lower film web.

Nowadays items of packaging often have a plurality of products which are separated from one another by a center film web. Items of packaging of this type are referred to as multiple-layer film items of packaging. DE 10 2005 048 491 B4 discloses a packaging machine for producing a multi-layer film item of packaging of this type. However, this packaging machine does not offer the possibility of shaping the center film.

It was, therefore, the object of the present invention to provide a packaging machine and a method which do not have the disadvantages of the prior art.

The object is achieved by a packaging machine with a sealing station which has an upper tool and a lower tool and which seals a center film web to a lower film web, wherein the upper tool and/or the lower tool of the sealing station have/has a means for shaping the center film web.

The present invention relates to a packaging machine with a sealing station which has an upper tool and a lower tool. Packaging machines of this type in particular serve to produce items of plastic packaging. In particular, the packaging machine according to the invention is suitable for producing a multiple-layer film item of packaging. In a multiple-layer film item of packaging, at least two products are packaged, separated by a center film. In the sealing station of the packaging machine according to the invention, a center film web is sealed to a lower film web. Here, the lower tool and the upper tool move toward one another. Sealing of the center film web to the lower film web typically takes place under exposure to heat and/or pressure.

It is now provided according to the invention for the upper tool and/or the lower tool to have a means for shaping the center film web. Shaping of the center film web preferably takes place prior to the latter being sealed to the lower film web. The connection between the center film web and the lower film web is preferably peelable, that is to say not welded in a fixed and/or integral manner, but releasable with little energy being applied.

On account of the upper tool and the lower tool having a means for shaping the center film web, shaping the center film web in a separate shaping station can be dispensed with. This considerably simplifies the packaging machine according to the invention.

The upper tool and/or the lower tool preferably have/has a heating zone for heating the center film web prior to shaping. This heating zone is preferably disposed in the vicinity of the sealing means, particularly preferably in the immediate vicinity of the sealing means, very particularly preferably adjacent to the sealing means, for example the sealing frame, of the upper tool and/or lower tool. The heating zone is preferably situated in the region of the upper tool. The heating zone may likewise preferably be embodied as a separately vertically driven unit or as a component of the die.

A die for shaping the center film web is preferably provided between the upper tool and/or the lower tool. This die is preferably movably, in particular vertically displaceably disposed on the upper tool. This die may preferably be temperature controlled, in particular heated or cooled. Particularly for optimizing the quality of shaping, the die may be equipped with ducts, via which a cushion of residual air may be suctioned off by means of vacuum units, so that the film lies against the die in the base region.

Very particularly preferably, the die has a shaping part which is movably, in particular horizontally displaceably, mounted in relation to the die. Preferably, this shaping part is displaceably mounted on the die and, driven by a drive, can move in two preferably opposing directions. By way of this shaping part, shaping of the center film web, in particular after having been pre-shaped by the die, can be supported. Using this shaping part, it is furthermore possible to simultaneously shape the center film web and the lower film web. On account thereof it is possible for a re-closure means to be molded-in on the center film web and on the lower film web. The shaping part is preferably heated.

According to a further preferred embodiment of the present invention, the upper tool and/or the lower tool have/has a compressed-air supply for shaping the center film web. By way of this gas supply, a positive pressure may be generated in particular above the center film web, which pressure presses the center film web in the direction of the lower film web. Here, the center film web preferably lies against a product placed on the lower film web and/or against the lower film web. Alternatively or additionally, this gas supply may also be employed for generating a negative pressure above the center film web. By means of this negative pressure, the center film web can be moved in the direction of the heating zone for improving the heat transfer between the heating zone and the center film web. The lower tool, at least in portions, is preferably designed as a racial for the center film web which is to be shaped.

The upper tool and/or the lower tool, in particular the upper tool, preferably have/has a movable shaping part for shaping the center film web or for supporting shaping of the latter. Preferably, this shaping part is displaceably mounted on the upper tool and, driven by a drive, can move in two preferably opposing directions.

Furthermore preferably, the packaging machine according to the invention has a further sealing station for sealing an upper film web to the center film web. This sealing takes place, in particular, after a further product has been placed on the center film web.

Furthermore preferably, the packaging machine according to the invention has two separate means, for example punches, for introducing gassing openings into the center film web and the lower film web. A gas exchange between the center film web and the lower film web and between the center film web and the upper film web may take place via these gassing openings. Preferably, the first means is provided ahead of the first sealing station and the second means following the first sealing station.

Furthermore preferably, the packaging machine according to the invention has two separate inserting stations. By way of the first inserting station, first products are in each case inserted into a packaging tray molded-in on the lower film web. By way of the second inserting station, second products are placed onto the center film web which is preferably also shaped as a tray.

Furthermore preferably, downstream of the second sealing station, the packaging machine according to the invention has a singularization station in which the completed items of packaging are in each case cut out from the lower film web, center film web and upper film web.

A further subject matter of the present invention is a method for sealing a center film web to a lower film web, in which the center film web is shaped, in particular prior to sealing, in a region between the upper tool and the lower tool.

The explanations made with respect to the packaging machine according to the invention apply in equal measure to the method according to the invention, and vice versa.

It is provided according to the invention that the center film web is shaped, in particular prior to sealing the center film web to the lower film web, in a region between the upper tool and the lower tool. On account thereof, a shaping station which is separate from the sealing station can be dispensed with, on account of which the method according to the invention can be carried out in a substantially simpler and a substantially more energy-efficient manner.

The center film web, prior to shaping, is preferably heated with a heating means. This heating means is preferably disposed in the upper tool.

Furthermore preferably, a packaging tray which is molded-in on the lower film web is filled, prior to sealing, with a first product.

A gas exchange preferably takes place prior to sealing the center film web to the lower film web. This gas exchange is preferably performed via clearances which have been introduced into the lower film web. Alternatively, this gas exchange may also be performed by means of a lance system which, in the industry, is referred to as a transverse nozzle bar.

Preferably after shaping the center film web and after sealing the center film web to the lower film web, a second product is placed onto the center film web, in particular into a tray molded-in on the center film web.

Thereafter, an upper film web is preferably sealed to the center film web in order to close the space above the second product.

A gas exchange in the space between the center film web and the upper film web preferably takes place prior to sealing the upper film web to the center film web. This gas exchange preferably takes place via clearances which nave been incorporated into the center film web after the latter has been sealed to the lower film web. Alternatively, this gas exchange may also be performed by means of a lance system.

A re-closure means is preferably molded-in between the center film web and the lower film web, in that the lower film web and the center film web are deformed substantially simultaneously, in particular by the same tool. This deformation preferably takes place after the center film web has been sealed to the lower film web. This re-closure means is preferably carried out by a shaping tool which is provided on a die, for example. This tool is preferably heated, such that the re-closure means is molded-in on the center film web and the lower film web by way of plastic deformation.

As a further embodiment of the present invention, the multiple-layer film items of packaging of interest here may also display two or more center film webs. With all embodiments, the upper film may also be shaped, either shaped downward in order to securely hold the topmost inserted product and to simultaneously obtain a more stable overall packaging, or shaped upward in order to achieve a more appealing design of the overall packaging.

In the case of the film webs of interest here, these may be any type of film or foil, respectively, which is known to a person skilled in the art of food technology; for example, the film is a soft or hard film from PP, PA/PE, PVC, A-Pet, paper, cardboard, metal or any other meaningful mixture and/or integrally interconnected layers of these components.

The invention will be explained in the following by means of FIGS. 1-5.

These explanations are only exemplary and do not limit the general concept of the invention. These explanations apply in equal measure to the packaging machine according to the invention and to the method according to the invention.

FIG. 1 shows the packaging machine according to the invention.

FIG. 2 shows a first embodiment of the first shaping/sealing station.

FIG. 3 shows a farther embodiment of the first shaping/sealing station.

FIG. 4 shows yet a further embodiment of the first shaping/sealing station.

FIG. 4 a shows the molding-in of the re-closure means.

FIG. 5 shows an embodiment of the second sealing station.

FIG. 1 shows the packaging machine according to the invention. A lower film web is, in particular cyclically, conveyed along this packaging machine, for example by way of two conveyor chains disposed to the left and to the right of the lower film web. First, by means of a shaping station 2, a packaging tray 16 is molded-in, for example by vacuum forming, on this lower film web 20. A first inserter 3 which inserts a first product (product 1) into the packaging tray 16 is provided downstream of the shaping station 2. Then, the filled item of packaging is conveyed into the first shaping/sealing station in which a center film web 17 is sealed, in particular in a peelable manner, to the lower film web 20. The center film web is deformed, in particular prior to sealing, as will yet be explained by means of FIGS. 2-4 a. If a gas exchange between the lower film web and the center film web prior to sealing is desired, one or more clearances via which the gas exchange preferably takes place are pierced into the lower film web, for example by punching, preferably upstream of the first shaping/sealing station. A second inserter 6 which inserts a second product (product 2) onto the center film web, in particular onto a tray molded-in on the center film web, is provided downstream of the first shaping/sealing station. Subsequently, in a second sealing station which is provided downstream of the second, inserter, an upper film web is sealed to the center film web. If a gas exchange between the upper film web and the center film web is desired, prior to sealing, openings have to be incorporated, in particular punched, into the center film web upstream of the second sealing station.

Finally, the items of packaging are singularized from the film webs 17, 20, 26 in a singularization station 7.

FIG. 2 shows a first embodiment of the first shaping/sealing station 4. The latter has a lower tool 28 and an upper tool 8 which, for sealing, are moved toward one another and, thereafter, for farther conveying of the film web 12, are removed from one another again. The lower tool 28 receives the packaging tray 16 molded-in on the lower film web 20. The lower film web 20 is situated between the lower tool 28 and the upper tool 8 and is conveyed perpendicularly to the paper plane into the paper plane. The center film 17, which is likewise provided perpendicularly to the paper plane and conveyed thereinto, is disposed above the lower film 20. The upper tool 8 which has a sealing means 12, here a sealing frame 12, for sealing the center film 17 to the lower film 20, is situated above the center film. This sealed seam is preferably peelable, i.e. easy to open by the user. Sealing preferably takes place with pressure and under exposure to heat which is made available, for example, by a heating medium 14. This heating means 14 heats, in particular, the sealing means 12, here the sealing frame. In order to be able to mold-in a tray on the center film web 17, as illustrated, a heating zone 13 which particularly preferably is likewise heated by the heating means 14 is preferably provided on the upper tool 8. By way of this heating zone, the center film web 17, so that it can then be plastically deformed, is heated, preferably up to its plasticization temperature. However, if applicable, even the heat of the sealing means 12 may be adequate for deforming the center film web. In order to improve the heat exchange between the heating zone 13 and the center film web 17, the center film web 17 is preferably placed in contact with the heating zone 13. This may take place, for example, in that a negative pressure is generated via the ducts 9. Deforming the center film web 17 may take place or be supported, for example, by way of a die 10 which is displaceably mounted in the upper fool 8. This die 10 preferably has a temperature-control means 11, in particular a coolant 11, in order to cool specific regions of the center film 17 and to prevent a run-off of material from the cooled region. Alternatively or additionally, deforming takes place by way of pressure, in particular air pressure, which is built up, for example, via the ducts 9 and presses the center film web 17 in the direction of the lower tool and of the product 1. This is symbolized by means of the arrows 18. For sealing the center film web to the lower film web, the upper tool and the lower tool are moved toward one another. Should a gas exchange prior to sealing be desired in the space between the center film web 17 and the lower film web 20 and in the region of the product 1, this preferably takes place via the clearance 29 in the lower film. Gas can be suctioned off and gas can be injected via this clearance, which is symbolized by the double arrow 19 and takes place by means of the gas-exchange duct 21.

FIG. 3 substantially shows the embodiment according to FIG. 2, wherein, in the present case, a displaceable element 22, for example a slide, is provided for supporting or carrying out the deformation of the center film on the upper tool 8. This element may be moved upward and downward, as is symbolized by the double arrow.

Also in the case of the embodiment according to FIG. 4, reference may substantially be made to the embodiment according to FIG. 2. In the present case, the die 10 has a movable element 23 which is provided so as to be movable, in particular horizontally movable, in relation to the die 10 and which supports or carries out shaping of the center film web 17.

In the case of the embodiment according to FIG. 4 a, reference may be made to the explanations according to FIGS. 2-4. In this figure, molding-in of a re-closure means on the lower film web 20 and on the center film web 17 is illustrated. This takes place by way of a shaping tool 24 which is preferably heated and which substantially simultaneously molds-in a shaping means and/or force-fitting means 31 on the lower film web 20 as well as on the center film web 17. To this end, the lower tool 28 preferably has a recess or notch 32, which acts as a counter bearing/shaping means for the tool 24.

FIG. 5 snows the second sealing station 6. This likewise has an upper tool and a lower tool, between which the lower film 20 and the center film 17, which is sealed to the lower film 20, and the upper film 26 are situated. All films 17, 20, 26 are conveyed perpendicularly to the paper plane into the paper plane. However, during sealing, these film webs are preferably static. Prior to sealing the upper film web 26 to the center film web 17, a second product (product 2) was inserted into the tray of the center film web 17. Should a gas exchange be desired, this takes place via a clearance 25 which has been incorporated into the center film web upstream of the second sealing station. The gas exchange is symbolized by the double arrow 19. For sealing, the lower tool and the upper tool are moved toward one another, and sealing takes place, as illustrated by the arrow 27, by means of a sealing frame 33 which is, in particular, heated.

LIST OF REFERENCE SIGNS

-   1 Packaging machine -   2 Shaping station -   3 First inserter -   4 First shaping/sealing station -   5 Second inserter -   6 Second sealing station -   7 Singularization -   8 Upper tool -   9 Gas/air duct -   10 Die -   11 Temperature control, cooling -   12 Sealing means, sealing frame -   13 Heating zone -   14 Heating medium -   15 Heating of film for deformation -   16 Packaging tray -   17 Film web, center film web -   18 Compressed-gas supply, compressed-air supply -   19 Gas exchange -   20 Lower film web -   21 Gas exchange duct -   22 Movable shaping part -   23 Movable shaping part -   24 Movable shaping part on die for producing a snap-fit closure -   25 Gassing opening in the center film -   26 Upper film web -   27 Sealing -   28 Lower tool -   29 Gassing opening in the lower film web -   30 Region between the upper tool and the lower tool -   31 Re-closure means -   32 Clearance -   33 Sealing means, sealing frame -   Product 1 First product -   Product 2 Second product 

1. A packaging machine comprising: a sealing station which has an upper tool and a lower tool and which seals a center film web to a lower film web, wherein the upper tool and/or the lower tool have/has a means for shaping the film web; wherein the packaging machine has a further sealing station for sealing the upper film web to the center film web; wherein the packaging machine has two separate means for introducing a gassing opening into the center film web and the tower film web; and Wherein the means for introducing the gassing openings into the center film web is provided upstream of the further sealing station.
 2. The packaging machine as claimed in claim 1, wherein the upper tool and/or the lower tool have/has a heating zone for heating the film web prior to shaping.
 3. The packaging machine as claimed in claim 1, wherein a die for shaping the film web is provided between the upper tool and/or the lower tool.
 4. The packaging machine as claimed in claim 3, wherein the die is temperature-controllable.
 5. The packaging machine as claimed in claim 3, wherein the die has a shaping part for shaping the film web and/or the lower film web which, is movable in relation to the die.
 6. The packaging machine as claimed in claim 1, wherein the upper tool and/or the lower tool have/has a compressed-gas supply for shaping the film web.
 7. The packaging machine as claimed in claim 1, wherein upper tool and/or the tower tool have/has a movable shaping part for shaping the film web.
 8. (canceled)
 9. (canceled)
 10. The packaging machine as claimed in claim 1, wherein the packaging machine has two inserting stations.
 11. The packaging machine as claimed in claim 1, wherein the packaging machine has a singularization station.
 12. A method for sealing a center film web to a lower film web, in which the center film web is shaped, in particular prior to sealing, in a region between the upper tool and the lower tool; wherein a re-closure means is molded-in between the center film web and the lower film web in that a shapeing tool simulteanously molds-in a front-fit means and/or force-fit means on the lower film web and on the center film web; and wherein prior to sealing, a gas exchange, which takes place via a clearance in the lower film web is performed.
 13. The method as claimed in claim 12, wherein the center film web, prior to shaping, is heated with a heating means.
 14. The method as claimed in claim 12, wherein a packaging tray which is molded-in on the lower film web is filled, prior to sealing, with a first product.
 15. (canceled)
 16. The method as claimed in claim 12, wherein a second product is placed onto the center film web.
 17. The method as claimed in claim 12, wherein an upper film web is sealed onto the center film web.
 18. The method as claimed in claim 17, wherein prior to sealing, a gas exchange is carried out in the space between the center film web and the upper film web.
 19. (canceled)
 20. The method as claimed in claim 13, wherein a packaging tray which is molded-in on the lower film web is filled, prior to sealing, with a first product.
 21. The method as claimed in claim 20, wherein a second product is placed onto the center film web.
 22. The method as claimed in claim 21, wherein an upper film web is sealed onto the center film web.
 23. The method as claimed in claim 21, wherein prior to sealing, a gas exchange is carried out in the space between the center film web and the upper film web.
 24. The method as claimed in claim 22, wherein prior to sealing, a gas exchange is carried out in the space between the center film web and the upper film web. 